Oxygen concentrator apparatus and method having flow restricted coupling of the canisters

Abstract

An oxygen concentrator may rely on a pressure swing adsorption process to produce an oxygen enriched gas stream from canisters filled with granules capable of separation of oxygen from an air stream. The adsorption process uses a cyclical pressurization and venting of the canisters to generate an oxygen enriched gas stream. The oxygen concentrator system may include one or more flow restrictors to allow controlled release of oxygen enriched gas between the canisters.

We claim: 
     
       1. A breathing apparatus for concentrating oxygen, comprising:
 at least a first canister and a second canister; 
 an adsorbent in the first canister and the second canister, wherein the adsorbent at least partially separates nitrogen from oxygen as air is passed through the first and/or second canister; 
 at least one compressor coupled to the first canister and the second canister, wherein at least one compressor, during use, sends air through compressor tubing into the first canister and the second canister; 
 a manifold comprising manifold tubing coupling at least one compressor to the first canister and the second canister; and 
 an additional plastic molded manifold coupled to the first and second canisters, wherein the additional plastic molded manifold comprises one or more molded channels to convey oxygen between the first canister and the second canister; 
 wherein at least a portion of the first canister, a portion of the second canister and a portion of the manifold are molded together to form a single molded component, wherein at least a portion of the manifold tubing is in the form of at least one molded channel in the molded component; and 
 wherein one or more of the molded channels in the additional plastic molded manifold define a first air pathway between the first canister and the second canister, the first air pathway comprising a first valve and a first flow restrictor; 
 wherein one or more of the molded channels in the additional plastic molded manifold define a second air pathway between the first canister and the second canister, the second air pathway comprising a second valve and a second flow restrictor; and 
 wherein the first air pathway and the second air pathway are operable to convey oxygen from the first canister to the second canister. 
 
     
     
       2. The breathing apparatus of  claim 1 , further comprising one or more valves coupled to the manifold tubing to control, during use, flow of gases through the manifold. 
     
     
       3. The breathing apparatus of  claim 1 , wherein at least a majority of the manifold tubing coupling the at least one compressor to the first canister and the second canister is integrated into the manifold. 
     
     
       4. The breathing apparatus of  claim 1 , wherein the first flow restrictor and/or the second flow restrictor are press fit flow restrictors, wherein the press fit flow restrictor is configured to be pressed into the air pathway between the first and/or second valve and the first or second canisters; and wherein the press fit flow restrictor is operable to narrow an effective radius of the air pathway receiving the press fit flow restrictor. 
     
     
       5. The breathing apparatus of  claim 1 , wherein the first air pathway and the second air pathway implement an air balance between the first and second canisters such that approximately an equal amount of oxygen is operable to be conveyed from the first canister to the second canister through the first air pathway and the second air pathway, when oxygen is under pressure in the first canister, as an amount of oxygen that is conveyed from the second canister to the first canister through the first air pathway and the second air pathway, when oxygen is under pressure in the second canister. 
     
     
       6. The breathing apparatus of  claim 1 , wherein the manifold further comprises at least two plastic injection molded valve seats. 
     
     
       7. A method of concentrating oxygen, comprising:
 transferring air into a first canister or a second canister of a breathing apparatus, from at least one compressor through a manifold of the breathing apparatus comprising manifold tubing coupling the at least one compressor to the first canister and the second canister, wherein:
 at least a portion of the first canister, at least a portion of the second canister, and a portion of the manifold are molded together to form a single molded component, wherein at least a portion of the tubing is in the form of at least one molded channel in the molded component; 
 wherein the breathing apparatus further comprises at least one additional plastic molded manifold coupled to the first and second canisters, wherein the additional plastic molded manifold comprises one or more molded channels to convey oxygen between the first canister and the second canister; 
 one or more of the molded channels in the additional plastic molded manifold define a first air pathway between the first canister and the second canister, the first air pathway comprising a first valve and a first flow restrictor; 
 one or more of the molded channels in the additional plastic molded manifold define a second air pathway between the first canister and the second canister, the second air pathway comprising a second valve and a second flow restrictor; and 
 the first air pathway and the second air pathway are operable to convey oxygen from the first canister to the second canister; 
 
 passing air through a first canister, wherein the first canister contains an adsorbent that at least partially separates nitrogen from oxygen as air is passed through the first canister; 
 receiving oxygen from the first canister; 
 passing air through a second canister, wherein the second canister contains an adsorbent that separates nitrogen from oxygen as air is passed through the second canister; and 
 receiving oxygen from the second canister. 
 
     
     
       8. The method of  claim 7 , further comprising controlling the flow of gases through the manifold using one or more valves disposed in the at least one molded channel. 
     
     
       9. The method of  claim 7 , further comprising monitoring a concentration of oxygen produced by the passage of air through the first and second canisters. 
     
     
       10. The method of  claim 7 , further comprising:
 venting nitrogen from the second canister, wherein at least part of the oxygen produced in the first canister is diverted through the second canister during at least part of the venting of the second canister. 
 
     
     
       11. The method of  claim 7 , further comprising:
 receiving an indication of a user inhalation through a pressure transducer, wherein the pressure transducer is operable to detect a change in pressure resulting from a start of a breath taken by the user; 
 providing oxygen to the user when the pressure transducer detects the start of a breath taken by the user.